Method of manufacturing circuit board

ABSTRACT

A method of manufacturing a circuit board includes the steps of preparing a fiber piece housing paste, fabricating a filtered recovery paste, fabricating a reuse paste, sticking a protective film, forming a hole, and filling the hole with the reuse paste. Furthermore, the method includes the steps of forming a protruded portion constituted of the reuse paste, disposing a metallic foil on both sides of a second prepreg to carry out pressurization, heating the second prepreg to cure the second prepreg and the reuse paste, and processing the metallic foil into a wiring pattern.

RELATED APPLICATIONS

This application is the U.S. National Phase under 35 U.S.C. §371 of International Application No. PCT/JP2012/002705, filed on Apr. 19, 2012, which in turn claims the benefit of Japanese Application No. 2011-099185, filed on Apr. 27, 2011, the disclosures of which Applications are incorporated by reference herein.

TECHNICAL FIELD

The present invention relates to a method of manufacturing a circuit board for connecting wiring patterns formed on both sides through a via, or a circuit board for connecting layers through a conductive paste.

BACKGROUND ART

In recent years, with a reduction in a size of an electronic component and an increase in a density, a double-sided board or a multilayer board is frequently used as a circuit board to be provided with an electronic component in place of a conventional single-sided board. As a structure of the circuit board, furthermore, an inner via hole structure is proposed in place of a connection of layers by a through hole processing and plating which are conventionally used widely. The inner via hole structure indicates a method of connecting layers by using a conductive paste, and high density wiring can be obtained. A method of manufacturing a circuit board using the conductive paste will be described with reference to FIGS. 14A to 15C. FIGS. 14A to 14D are sectional views for explaining the method of manufacturing a circuit board by using the conductive paste.

FIG. 14A shows a section of prepreg 1 having protective film 2 provided on both sides. FIG. 14B shows a state in which hole 3 is provided on prepreg 1 illustrated in FIG. 14A. FIG. 14C shows a state in which prepreg 1 having hole 3 formed thereon is fixed to base 6 and jig 4 of a squeegee formed by rubber (or a rub-in rubber plate) is moved in a direction of arrow 7 to fill hole 3 with conductive paste 5. FIG. 14D shows a state in which protective film 2 is peeled from both sides of prepreg 1 and protruded portion 8 formed by conductive paste 5 is provided.

FIGS. 15A to 15C are sectional views for explaining a method of manufacturing a both-sided board using a conductive paste, illustrating subsequent steps to FIG. 14D.

FIG. 15A shows a state in which copper foil 9 is disposed on both sides of prepreg 1 provided with protruded portion 8, and pressurization and integration are carried out as shown in arrow 71 by using a press device (not shown). In the integration, heating is also useful. By providing protruded portion 8 on conductive paste 5, it is possible to compress and bond conductive powder particles contained in conductive paste 5 at a high density.

FIG. 15B is a sectional view showing a state brought after copper foil 9 is integrated through prepreg 1 or conductive paste 5. In FIG. 15B, insulating layer 10 is formed by heating and curing prepreg 1. In via 11, the conductive powder particles contained in conductive paste 5 are compressed, deformed, and bonded to each other.

FIG. 15C shows a state in which copper foil 9 of FIG. 15B is subjected to etching to form wiring 12 having a predetermined pattern. Then, a solder resist or the like (which is not shown) is formed so that a double-sided board is manufactured.

Patent Documents 1 and 2 are known as prior art documents related to the present invention.

CITATION LIST Patent Literature

-   PTL 1 Unexamined Japanese Patent Publication No. 6-268345 -   PTL 2 Unexamined Japanese Patent Publication No. 2002-171060

SUMMARY OF THE INVENTION

A method of manufacturing a circuit board according to the present invention includes the steps of preparing a fiber piece housing paste including a conductive paste having conductive powder and a resin, and a fiber piece taken away from a first prepreg, and filtering the fiber piece housing paste in a paste state by using a filter for fabricating a filtered recovery paste. Furthermore, the method includes the steps of adding at least one of a solvent, a resin, and a paste having a different composition from the filtered recovery paste to the filtered recovery paste for fabricating a reuse paste, and sticking a first protective film to a surface of a second prepreg. Moreover, the method includes the steps of forming a first hole on the second prepreg through the first protective film, filling the first hole with the reuse paste, and peeling the first protective film to form a protruded portion constituted of the reuse paste on the surface of the second prepreg. In addition, the method includes the steps of disposing a metallic foil on both sides of the second prepreg to pressurize the second prepreg from an outside of the metallic foil, heating the second prepreg to cure the second prepreg and the reuse paste, and processing the metallic foil into a wiring pattern.

BRIEF DESCRIPTION OF DRAWINGS

FIG. 1A is a sectional view for explaining a state in which a fiber piece stuck onto a first protective film is recovered into a conductive paste.

FIG. 1B is a sectional view for explaining a state in which a fiber piece stuck onto a first protective film is recovered into a conductive paste.

FIG. 1C is a sectional view for explaining the state in which the fiber piece stuck onto the first protective film is recovered into the conductive paste.

FIG. 2A is a sectional view for explaining a state in which a hole of a first prepreg is filled with the conductive paste.

FIG. 2B is a sectional view for explaining a state in which a hole of a first prepreg is filled with the conductive paste.

FIG. 3A is a sectional view for explaining an example of a method of manufacturing a circuit board.

FIG. 3B is a sectional view for explaining an example of a method of manufacturing a circuit board.

FIG. 3C is a sectional view for explaining an example of the method of manufacturing a circuit board.

FIG. 4A is a sectional view for explaining the case in which a large number of fiber pieces are mixed into a conductive paste.

FIG. 4B is a sectional view for explaining the case in which a large number of fiber pieces are mixed into a conductive paste.

FIG. 5A is a sectional view for explaining the case in which a via constituted of the conductive paste has an unfilled portion or an air gap.

FIG. 5B is a sectional view for explaining the case in which a via constituted of the conductive paste has an unfilled portion or an air gap.

FIG. 5C is a sectional view for explaining the case in which the via constituted of the conductive paste has the unfilled portion or the air gap.

FIG. 6 is a typical view for explaining a state in which a paste which is conventionally discarded is reproduced as a reuse paste.

FIG. 7 is a typical view for explaining a state in which a recovered composite paste is filtered and a filtered recovery paste is thus manufactured.

FIG. 8 is a typical view for explaining a state in which a solvent or the like is added to the filtered recovery paste and is thus manufactured as a reuse paste.

FIG. 9A is a sectional view for explaining a state in which a second hole formed on a second prepreg is filled with the reuse paste through a second protective film.

FIG. 9B is a sectional view for explaining a state in which a second hole formed on a second prepreg is filled with the reuse paste through a second protective film.

FIG. 10A is a sectional view for explaining a state in which a second circuit board is manufactured by using the reuse paste.

FIG. 10B is a sectional view for explaining a state in which a second circuit board is manufactured by using the reuse paste.

FIG. 10C is a sectional view for explaining the state in which the second circuit board is manufactured by using the reuse paste.

FIG. 11A is a view for explaining a method of manufacturing a multilayer board having four wiring layers.

FIG. 11B is a view for explaining a method of manufacturing a multilayer board having four wiring layers.

FIG. 11C is a view for explaining the method of manufacturing a multilayer board having four wiring layers.

FIG. 12A is a view showing an SEM observation image of the recovery paste.

FIG. 12B is a typical view of FIG. 12A.

FIG. 13A is a typical view for explaining an experiment example of a conductive paste according to a comparative example.

FIG. 13B is a typical view for explaining an experiment example of a conductive paste according to a comparative example.

FIG. 13C is a typical view for explaining the experiment example of the conductive paste according to the comparative example.

FIG. 14A is a sectional view for explaining a method of manufacturing a circuit board using a conductive paste according to the related art.

FIG. 14B is a sectional view for explaining a method of manufacturing a circuit board using a conductive paste according to the related art.

FIG. 14C is a sectional view for explaining the method of manufacturing a circuit board using a conductive paste according to the related art.

FIG. 14D is a sectional view for explaining the method of manufacturing a circuit board using a conductive paste according to the related art.

FIG. 15A is a sectional view for explaining a method of manufacturing a double-sided board using a conductive paste, illustrating a step subsequent to FIG. 14.

FIG. 15B is a sectional view for explaining a method of manufacturing a double-sided board using a conductive paste, illustrating a step subsequent to FIG. 14.

FIG. 15C is a sectional view for explaining the method of manufacturing a double-sided board using a conductive paste, illustrating a step subsequent to FIG. 14.

DESCRIPTION OF EMBODIMENTS

FIGS. 1A to 1C, FIG. 2A and FIG. 2B are sectional views for explaining a state in which a fiber piece constituted of a part of a glass fiber or a resin fiber and sticking onto a protective film is recovered into a conductive paste.

FIGS. 1A to 1C are sectional views for explaining a state in which a fiber piece constituted of a glass fiber or a resin fiber such as aramid and sticking onto a first protective film is recovered into a conductive paste. First prepreg 101 is formed in a semi-curing state (that is, a B stage state) by impregnating a glass woven fabric, a glass non-woven fabric, an aramid fabric or an aramid non-woven fabric with an epoxy resin or the like. First protective film 102 is a PET film or the like. For first protective film 102, more specifically, PET (polyethylene terephthalate), PEN (polyethylene naphthalate), PPS (polyphenylene sulfide) or the like is used. First protective film 102 is formed on a surface of first prepreg 101 through thermocompression bonding while removing air by using a vacuum laminater or a roll laminater. First hole 103 is formed by a carbon dioxide laser, a YAG laser or the like. In the case in which large first hole 103 is formed, moreover, a drill, a punch or the like may be used. Jig 104 is a squeegee rubber or the like.

Conductor paste 105 has conductive powder, a main agent and a curing agent. As the conductive powder, for example, there is used copper powder having an average particle diameter of 0.5 μm or more and 20 μm or less, a specific surface area of 0.1 m²/g or more and 1.5 m²/g or less, or the like. As the main agent, for example, there is used a liquid epoxy resin. As the curing agent, for example, there is used a latent curing agent or the like. Conductive paste 105 contains the conductive powder in 80% by weight or more and 92% by weight or less, the main agent in 4.5% by weight or more and 17% by weight or less, and the curing agent in 0.5% by weight or more and 5% by weight or less.

Conductive powder 105 may be silver powder, alloy powder, solder powder, Ag coating powder or their mixture which has an average particle diameter of 0.5 μm or more and 20 μm or less.

Fiber piece 108 is a foreign substance which drops out of a cut surface of first prepreg 101, has an epoxy resin in a semi-curing state or the like sticking thereto and is formed of a glass fiber or a fiber such as aramid, and may be a fiber piece group to which a plurality of fiber pieces is bound thereto through a resin.

In FIG. 1A, first protective film 102 is applied to both sides of first prepreg 101. Fiber piece 108 sticks to a surface of first protective film 102. In the case in which a plurality of first prepregs 101 is stacked in a thickness direction, they stick to the surface of prepreg 101 with static electricity or the like. Even if fiber piece 108 is removed by a suction device or an adhesive roll (neither of which are shown in the drawing), new fiber piece 108 sticks to the surface of first prepreg 101 when first prepregs 101 or the like are stacked in the thickness direction or when they are individually peeled therefrom, or with static electricity generated in handling, for example, friction in delivery or the like. Also after the removal through the sucking device or the adhesive roll, thus, a new semi-cured epoxy resin or fiber piece 108 drops out of a side surface of the prepreg or the like and sticks, as a new foreign substance, onto first protective film 102 formed on the both sides of first prepreg 101 with static electricity or the like. For this reason, a countermeasure against the static electricity is required to be taken every step in a process for manufacturing a circuit board. Also in some cases in which the static electricity of first protective film 102 is removed by an electrostatic blower or the like, moreover, it is newly charged with the static electricity in handling of a next step, stacking or individual peeling.

FIG. 1B shows a state in which first protective film 102 and first hole 103 are formed on first prepreg 101. First hole 103 may be a through hole as shown or a bottomed hole (not shown) depending on uses. Also in a processing of first hole 103 of first prepreg 101, delivery of a base material which is accompanied by the processing or handling, new fiber piece 108 sticks to the surface of first protective film 102.

FIG. 1C shows a state in which jig 104 is moved in a direction shown in arrow 107 over first protective film 102 having fiber piece 108 sticking thereto, and first hole 103 is thus filled with conductive paste 105. By raising a pressure of jig 104 against first protective film 102, it is possible to increase a push power of conductive paste 105 into first hole 103. Furthermore, fiber piece 108 on first protective film 102 can be accommodated in conductive paste 105 to form fiber piece housing paste 109. Referring to fiber piece housing paste 109 accommodating fiber piece 108 in a small amount, moreover, it is possible to push conductive paste 105 into first hole 103 by raising a pressure of jig 104 against first protective film 102 as shown in FIG. 1C.

It is desirable that jig 104 should be pushed by a certain pressure or more so as to be bonded to the surface of first protective film 102. By setting jig 104 to have the certain pressure or more, it is possible to decrease the amount of conductive paste 105 (not shown) which is left as a residue on the surface of first protective film 102. As a result, it is possible to decrease conductive paste 105 to be discarded in a sticking state to first protective film 102.

In order to decrease the amount of conductive paste 105 to be discarded in a sticking state to the surface of first protective film 102, it is desirable to certainly scrape away a conductive particle contained in conductive paste 105 so as not to be left on the surface of first protective film 102. As the conductive particle, for example, a copper particle having a particle diameter of approximately 1 μm to 10 μm is used. When the scraping is carried out over first protective film 102 by means of jig 104 more certainly, fiber piece 108 sticking onto first protective film 102 is accommodated in conductive paste 105 more greatly. In some cases, fiber piece 108 has a diameter which is equal to or greater than 1 μm, furthermore, 5 μm, or is almost equal to or greater than the particle diameter of the copper particle.

FIGS. 2A and 2B are sectional views for explaining a state in which first hole 103 of first prepreg 101 is filled with conductive paste 105. By using jig 104, fiber piece 108 is accommodated in conductive paste 105 to be filled in first hole 103 so that fiber piece housing paste 109 is formed.

As shown in FIG. 2B, jig 104 is moved in a direction shown in arrow 207 to fill first hole 103 with conductive paste 105. In FIG. 2B, it is useful to vacuum suck conductive paste 105 on base 106 side as shown in arrow 107 b. In the case in which the amount of fiber piece 108 accommodated in conductive paste 105 is large, a viscosity of fiber piece housing paste 109 is increased. As a result, the filling of conductive paste 105 in first hole 103 in FIG. 2B is influenced in some cases. In those cases, a vacuum sucking hole or the like is provided on base 106 to suck conductive paste 105 into first prepreg 101 as shown in arrow 107 b through a ventilation sheet (for example, a paper or the like) so that a filling property thereof can be enhanced.

In some cases in which a member having a selective permeability for a component of conductive paste 105 is used for the ventilation sheet, only a component in a part of conductive paste 105 is selectively absorbed through the ventilation sheet. For this reason, a composition of fiber piece housing paste 109 tends to be influenced. The component of conductive paste 105 includes a liquid component or a solvent component, for example. The composition of fiber piece housing paste 109 includes a solid content or a ratio of the liquid component, for example.

FIGS. 3A to 3C are sectional views for explaining an example of the method of manufacturing a circuit board, illustrating an example of subsequent steps to the manufacturing method of FIG. 2B.

FIG. 3A is a sectional view showing a state in which first copper foil 110 is disposed on both sides of first prepreg 101 provided with first protruded portion 111 formed by conductive paste 105 as a metallic foil. By adjusting a thickness of first protective film 102 in FIG. 2A, FIG. 2B or the like, it is possible to increase/decrease a thickness of first protruded portion 111. First copper foil 110 is disposed on the both sides of first prepreg 101 provided with first protruded portion 111 and is pressurized and integrated as shown in arrow 307 by using a pressing device (not shown). In the integration, heating is also useful. By providing first protruded portion 111 on conductive paste 105, it is possible to compress and closely bond conductive powder particles contained in conductive paste 105 at a high density.

FIG. 3B is a sectional view for explaining a state brought after the lamination. First insulating layer 112 is a product obtained by curing first prepreg 101. First via 113 is a product obtained by curing conductive paste 105. First via 113 is strongly pressurized and compressed corresponding to the thickness of first protruded portion 111. For this reason, conductive powder particles such as copper powder particles contained in conductive paste 105 are deformed and come in face contact with each other. As a result, the via portion has a low resistance.

In FIG. 3C, first wiring 114 is formed by patterning first copper foil 110 into a predetermined shape. First circuit board 115 has first insulating layer 112, first wiring 114 fixed to the both sides of first insulating layer 112, and first via 113 for connecting first wirings 114.

By setting first circuit board 115 as a core substrate to laminate an insulating layer, a wiring or the like on the both sides, it is possible to form a multilayer.

FIGS. 4A and 4B are sectional views for explaining the case in which a large number of fiber pieces 108 is mixed into conductive paste 105. In FIG. 4A, a large number of fiber pieces 108 are mixed into conductive paste 105. Every time squeegeeing is carried out over first protective film 102 by means of jig 104 to which conductive paste 105 is stuck, fiber piece 108 is increased on an integration basis. A part of fiber piece 108 stuck to the surface of first protective film 102 at a step of filling conductive paste 105 is stuck to jig 104. Moreover, fiber piece 108 which cannot be completely removed at the previous step is stuck to the surface of first protective film 102 in which first hole 103 is not filled with conductive paste 105.

FIG. 4B shows a state in which a part of fiber piece 108 stuck to first protective film 102 is further mixed into conductive paste 105 when conductive paste 105 is to be filled in first hole 103 formed on first protective film 102 or first prepreg 101. When fiber piece 108 is mixed, a viscosity of conductive paste 105 is increased. For this reason, there is a possibility that a filling property of conductive paste 105 into first hole 103 might be influenced, resulting in generation of unfilled portion 137 or air gap 138. In FIG. 4B, unfilled portion 137 indicates an insufficient filled portion in an opening state of conductive paste 105. Moreover, air gap 138 indicates an insufficient filled portion in a closing state of conductive paste 105. In some cases in which new conductive paste 105 is supplied onto unfilled portion 137 by means of jig 104, furthermore, air gap 138 is generated.

FIGS. 5A to 5C are sectional views for explaining the case in which first via 113 having conductive paste 105 formed therein has unfilled portion 137 and air gap 138. In FIG. 5A, first prepreg 101 is filled with conductive paste 105 having unfilled portion 137 or air gap 138. In the case of conductive paste 105 having unfilled portion 137, the protrusion of first protruded portion 111 is reduced corresponding to unfilled portion 137. In some cases of conductive paste 105 having air gap 138, moreover, a compression force is reduced by the influence of air gap 138 in pressurization even if the protrusion of first protruded portion 111 of conductive paste 105 is sufficient.

FIG. 5B is a sectional view for explaining the influence of conductive paste 105 having unfilled portion 137 and air gap 138. FIG. 5C is a sectional view for explaining a state brought after first copper foil 110 in FIG. 5B is subjected to patterning and first wiring 114 is thus formed.

In FIGS. 5B and 5C, first insulating layer 112 is obtained by curing first prepreg 101, and first via 113 is obtained by curing conductive paste 105. Unfilled portion 137 influences the contact of an interface portion between first via 113 and first copper foil 110. Moreover, air gap 138 influences an inner part of first via 113. There is a possibility that a resistance of first via 113 might be raised in respective portions. In other words, the compression of conductive paste 105 is insufficient and the contact between the conductive powder particles is deficient so that a contact resistance is raised.

As described above, in some cases in which first hole 103 formed on first prepreg 101 is filled with conductive paste 105 through first protective film 102, fiber piece 108 stuck to first prepreg 101 is mixed into conductive paste 105 so that electrical characteristics are influenced. This becomes more remarkable with decrease in a diameter of the via.

Such a problem caused by fiber piece 108 rarely arises in a screen printing method which is widely used in manufacture of a circuit board or the like. The reason is that a screen printing plate (particularly, an emulsion used therein) prevents the contact of fiber piece 108 with conductive paste 105 in the case of the printing method. Also in the method of manufacturing a circuit board which connects layers through plating according to the related art, moreover, the problem rarely arises.

As shown in FIGS. 1A to 1C, FIG. 2A and FIG. 2B, when conductive paste 105 is to be subjected to squeegeeing (or to be rubbed in) over first protective film 102, fiber piece 108 sticking to first protective film 102 is mixed into conductive paste 105. Conductive paste 105 having fiber piece 108 mixed therein is changed into fiber piece housing paste 109. In the case in which the amount of fiber piece 108 accommodated in fiber piece housing paste 109 exceeds a certain amount, fiber piece 108 is conventionally discarded as a waste paste.

In recent years, increase in a density of a circuit board and reduction in a diameter of the via are demanded. If the diameter of the via is reduced more greatly, a resistance of the via or the like is influenced by the mixture of the fiber piece more easily. For this reason, the conductive paste having the fiber piece mixed therein is discarded.

First prepreg 101 contains a fiber of glass or aramid and a resin in a semi-curing state. Since an epoxy resin in the semi-curing state is uncured, it is fragile, small and broken easily. Moreover, an opening processing for loosening a fiber is carried out in order to impregnate the fiber with the epoxy resin without an air bubble. For this reason, fiber piece 108 or a resin in a semi-curing state which is stuck to a fiber tends to be taken away from a side surface or a cut surface of first prepreg 101.

Furthermore, the resin or fiber piece 108 which is taken away tends to be stuck to a surface of another stacked first prepreg 101 with static electricity or the like. The reason is that all of first prepreg 101, fiber piece 108 and the resin in the semi-curing state are insulators and are easily charged with the static electricity. Moreover, several ten first prepregs 101 (taking a shape of a sheet of 500 mm×600 mm, for example) are stacked in a thickness direction before manufacture and are peeled one by one in the manufacture, and are singly processed in many cases. For this reason, first prepreg 101 tends to be changed with the static electricity in the stacking or peeling work, and fiber piece 108 taken away from the side surface of first prepreg 101 or the like is stuck to first prepreg 101. Even if fiber piece 108 is removed by means of an adhesive roll or the like at a certain step, moreover, new fiber piece 108 is stuck when first prepreg 101 is charged at a next step in some cases. When first prepregs 101 subjected to static electricity removal are laminated and are then peeled one by one, furthermore, static electricity is generated newly.

A state in which a waste paste is recycled will be described with reference to FIGS. 6 to 8.

FIG. 6 is a typical view for explaining a state in which a paste to be discarded conventionally is reproduced and used again as a reuse paste.

Recovery pastes 119 a to 119 d are used at separate squeegeeing steps or separate conductive paste filling steps or are used pastes sticking to separate jigs 104, and are conventionally treated as industrial wastes.

Recovery pastes 119 a to 119 d have composition deviation pastes 116 a to 116 d in which composition deviation is generated due to squeegeeing or the like and fiber pieces 108 a to 108 d, respectively.

A large number of recovery pastes 119 a to 119 d are generated in small amounts at the respective steps. Referring to composition deviation pastes 116 a to 116 d included in recovery pastes 119 a to 119 d, moreover, a composition rate of conductive powder, a resin or the like which is contained therein deviates form a standard value in a manufacturing specification. Conductor paste 105 has conductive powder, a main agent and a curing agent. When the number of times of print is increased, fiber piece 108 in conductive paste 105 is increased so that a composition deviates.

A composition rate is changed depending on a squeegeeing condition (or a rub-in condition), a frequency of use of a paste or the influence of first protective film 102, first hole 103 or the like. In addition, types or amounts of fiber pieces 108 a to 108 d contained in recovery pastes 119 a to 119 d are varied depending on a difference in a type of a base material, an environment, a processing device or a handling device, or the like.

A plurality of different lots or fiber piece housing paste 109 accommodating a plurality of fiber pieces obtained at the squeegeeing step in a large amount is recovered as a plurality of recovery pastes 119 a to 119 d. Then, they are collected into one so that recovered composite paste 120 is obtained.

By recovering plural types of used pastes and unifying them into one to form recovered composite paste 120, it is possible to increase an amount of reproduction per time. As a result, a cost of the reproduction can be reduced. Recovered composite paste 120 contains various fiber pieces 108 a to 108 d.

By recovering, as a single batch, recovery pastes 119 a to 119 d having different compositions from each other or the like, it is possible to reduce a waste generated at a reproducing step.

Even if recovery pastes 119 a to 119 d can be recovered in a small amount, that is, approximately 10 g to 50 g every lot, it is possible to increase the amount of recovered composite paste 120 to be 1 kg to 10 kg or more by periodically collecting a plurality of small lots if necessary. As a result, it is possible to increase a yield in recycling for reducing a processing cost. Herein, the plural number indicates 10 to 100 lots or more, for example.

FIG. 7 is a typical view for explaining a state in which recovered composite paste 120 is filtered to manufacture filtered recovery paste 122. A net-like mesh formed of stainless, polyester, or the like is used as filter 121. Various fiber pieces 108 a to 108 d mixed into recovered composite paste 120 are removed by filter 121. In other words, recovered composite paste 120 is filtered in a direction of arrow 407 so that filtered recovery paste 122 is obtained. At the filtering step, it is possible to increase a filtering speed by using vacuum suction, a rotary push-in blade or screw, a pressure pump for a slurry, a diaphragm pump and the like (which are not shown) together. As the vacuum suction, for example, there is used a vacuum pump, an aspirator for reducing a pressure by the Venturi effect utilizing a fluid, or the like.

At the step of filtering recovered composite paste 120, it is desirable to regulate an opening size of filter 121. More specifically, it is desirable to set the opening size of filter 121 to be three times as great as an average diameter of a metal particle contained in recovered composite paste 120 or more and to be twenty times as great as an average diameter of a fiber constituting first prepreg 101 or less, and furthermore, ten times or less, and furthermore, five times or less. The reason is as follows. In the case in which a fiber such as a glass fiber is contained as a foreign substance in recovered composite paste 120, a length of the glass fiber to be the foreign substance is twenty times as great as an average diameter of the glass fiber or more, and furthermore, fifty times or more.

Moreover, it is preferable that a latent curing agent should be used as a curing agent in conductive paste 105. It is preferable that the opening diameter of filter 121 should be three times as great as an average particle diameter of a metallic particle or more, be twenty times as great as an average diameter of fiber piece 108 or less, and be a double of a diameter of the latent curing agent or more.

For example, several types of amine and an epoxy resin are reacted with each other and are thus changed into particles so that the latent curing agent is fabricated. The latent curing agent can be preserved without a change in a property for a long period of time at a room temperature, and is cured by heating to a predetermined temperature or more. By using the latent curing agent, it is possible to carry out more stable printing also in the case in which the number of times for recovering conductive paste 105 is large.

By adding an organic solvent in a small amount or the like to recovered composite paste 120 if necessary, moreover, it is possible to reduce a viscosity of recovered composite paste 120. As a result, a filter working property of filter 121 can be enhanced. Furthermore, it is preferable that the organic solvent added for filtering or the like should be properly taken away from a solvent to be added later to filtered recovery paste 122 or the like correspondingly if necessary. Thus, recovered composite paste 120 in a paste state is filtered as it is.

FIG. 8 is a typical view for explaining a state in which solvent or the like 123 is added to filtered recovery paste 122 to manufacture reuse paste 124.

Solvent or the like 123 is at least one of a solvent, a resin and a paste having a different composition from the filtered paste. For the solvent, there is used the same solvent as that contained in the conductive paste. Alternatively, diethylene glycol monobutyl ether acetate having another name of butyl carbitol acetate or the like is used as the solvent. For the resin, there is used the same resin as that contained in the conductive paste. For the resin, alternatively, there is used an epoxy resin or the like. Solvent or the like 123 may be added and mixed at a time or separately at plural times. After a viscosity is reduced, moreover, filtering may be carried out to obtain filtered recovery paste 122. Reuse paste 124 is a conductive paste which is reproduced for reuse by removing fiber piece 108 from the used conductive paste without influencing a shape of copper powder contained therein or the like. It is useful to adjust reuse paste 124 to have a composition, a solid content, a viscosity or the like which is almost identical to new conductive paste 105 described with reference to FIG. 1C or the like. However, reuse paste 124 contains a very small fiber piece or the like which is not contained in new conductive paste 105 in some cases. For this reason, it is useful to cause a difference between conductive paste 105 and reuse paste 124 to be clear through analysis. More specifically, TG/DTA is used to discharge an organic component for measuring a content rate of an inorganic component. As compared with a content rate of initial conductive paste 105, a deficient weight of a resin is calculated and the resin is added to reuse paste 124. Herein, the very small fiber piece or the like has a length which is almost equal to a diameter thereof or is approximately a double of the diameter, for example.

Solvent or the like 123 may be a liquid thermosetting resin or other conductive pastes in addition to an organic solvent. In the case in which the conductive paste is used as solvent or the like 123, it is useful to utilize the other conductive paste having a viscosity or a composition ratio which is different from that of conductive paste 105 described with reference to FIG. 1C or the like. A composition ratio of the conductive paste contained in filtered recovery paste 122 is greatly deviated from a viscosity, a composition ratio or the like of initial conductive paste 105. In order to correct the deviation, it is desirable to add the other conductive paste having a viscosity or a composition ratio which is different from that of initial conductive paste 105.

It is useful to utilize a kneading device (for example, a planetary mixer or a roll kneading device) in order to mix filtered recovery paste 122 with solvent or the like 123.

Herein, it is desirable to use a viscometer for adjusting a viscosity (or measuring the viscosity). Moreover, it is desirable to use a solid content meter for adjusting a composition ratio (or measuring the composition ratio) or to use a thermal analysis device (which is referred to as DSC, TG, DTA or the like). In the case in which the conductive powder contained in recovery pastes 119 a to 119 d is a base metal (for example, copper), moreover, it is useful to measure and adjust the composition ratio through thermogravimetry (TG) in a nitrogen atmosphere in order to prevent the influence of oxidation of the conductive powder.

The composition ratio indicates an amount of conductive powder in a paste (weight %), an amount of a volatile matter in a paste (weight %), an amount of an organic matter in a paste (weight %) or the like. Moreover, a specific gravity of the paste is greatly influenced by a content rate of a metal contained in the paste. For this reason, reference may be made to the specific gravity of the paste. In the case in which the specific gravity is measured, it is also possible to use a floating method, pychnometry, a vibration type density meter, a balance method or the like based on JIS K 0061 (a method of measuring a density and a specific gravity of a chemical product). In the case in which a pycnometer method is used, a specific gravity bottle put on the market may be utilized. Herein, a Wadon type, Gay-Lussac type, LeCharite type or JIS K 2249 Harvard type specific gravity bottle is used for measuring specific gravities of liquid and semisolid road tars having comparatively high viscosities. In the case of a paste having a high viscosity, moreover, it is also useful to originally make a specific gravity bottle itself. In the case in which a specific gravity bottle having a volume of approximately 1 cc to 100 cc is originally made, it is useful to utilize a metallic material such as stainless. By originally making a specific gravity bottle made of stainless or the like, it is possible to prevent a damage during measurement or in handling or the like and to carry out wipe cleaning through a solvent or the like.

It is useful that a fiber having a length which is equal to or greater than ten times as great as the average particle diameter of the conductive powder contained in fiber piece housing paste 109 possesses 50 wt % or more of all fiber pieces 108. The reason is that the fiber having the length which is ten times as great as the average particle diameter of the conductive powder or more can be removed easily at the filtering step. In the case in which the fiber having the length which is ten times as great as the average particle diameter of the conductive powder or more possess a rate of less than 50 wt % of all fiber pieces 108 contained in fiber piece housing paste 109, that is, a large number of fiber pieces have lengths which are smaller than ten times as great as the average particle diameter of the conductive powder, a high rate of the fiber pieces contained in reuse paste 124 is increased. In other words, the number of short fiber pieces which cannot be removed through the filtering is increased. As a result, the characteristic of reuse paste 124 is influenced in some cases.

In addition, it is useful that fibers having lengths which are ten times as great as the average particle diameter of the conductive powder or more and are less than 100 times as great as the average particle diameter of the conductive powder possess a rate of 50 wt % or more of all fiber pieces 108 and a rate of less than 90 wt %. In some cases in which a fiber having a length which is 100 times as great as the average particle diameter of the conductive powder or more is present or a fiber having a length which is 10 times as great as the average particle diameter or more possesses a rate of 90 wt % or more, the filtering is hard to perform. If the fiber having the length which is ten times as great as the average particle diameter of the conductive powder or more contained in fiber piece housing paste 109 is set to possess a rate of 0.01 wt % or more and 10 wt % or less of fiber piece housing paste 109, moreover, reuse paste 124 can be manufactured easily. In some cases in which an amount of the fiber having the length which is ten times as great as the average particle diameter of the conductive powder or more contained in fiber piece housing paste 109 is less than 0.01 wt % of fiber piece housing paste 109, it is impossible to obtain an effect for removing a long fiber in the filtering step. In some cases in which the amount is equal to or more than 10.00 wt %, furthermore, the filtering is hard to perform.

It is desirable that fiber piece 108 contained in fiber piece housing paste 109 should be a glass fiber or an aramid fiber. The glass fiber possesses a part of a glass woven fabric or a nonwoven glass fabric which constitutes a core of a prepreg. Moreover, the aramid fiber also possesses a part of an aramid woven fabric or a nonwoven aramid fabric which constitutes the core of the prepreg.

Furthermore, it is desirable that an opening diameter of a filter to be used in the filtering should be set to be three times as great as the average particle diameter of the conductive powder contained in fiber piece housing paste 109 or more and to be twenty times as great as the average diameter of fiber piece 108 or less. In some cases in which the opening diameter is less than three times as great as the average particle diameter, a filtering property of the conductive powder is influenced. In some cases in which the opening diameter exceeds twenty times as great as the average diameter of the fiber piece, furthermore, a removing property of a long fiber is influenced.

It is useful that a temperature of fiber piece housing paste 109 is maintained within a range of a temperature region of 0° C. to 80° C. in the filtering step. In the case in which the temperature is lower than 0° C., it is necessary to take care of handling. In some cases in which the temperature exceeds 80° C., a thermosetting resin contained in reuse paste 124 starts to be cured.

It is useful that a rate of a fiber having a length which is ten times as great as the average particle diameter of the conductive powder or more is set to be 10 wt % of all of the fiber pieces or less in reuse paste 124. By setting the rate of the long fiber to be 10% wt or less, and furthermore, 5 wt % or less, it is possible to reduce a rise in a viscosity in a manufacturing process in manufacturing a circuit board using reuse paste 124.

It is useful that a rate of a fiber piece having a length which is less than three times as great as the average particle diameter of the conductive powder contained in reuse paste 124 is reduced to be 5 wt % or less of a weight of all reuse pastes 124. By setting the rate to be 5 wt % or less, it is possible to reduce the rise in the viscosity in the manufacturing process in manufacturing the circuit board using reuse paste 124.

Next, a state in which a second circuit board is manufactured by using reuse paste 124 thus fabricated will be described with reference to FIGS. 9A to 11C. The second circuit board uses reuse paste 124 obtained by reproducing, as shown in FIGS. 6 to 8, conductive paste 105 used for fabricating the first circuit board, that is, conductive paste 105 which is conventionally discarded due to the mixture of a large number of fiber pieces 108.

FIGS. 9A to 11C are sectional views for explaining the state in which the second circuit board is manufactured by using reuse paste 124.

FIGS. 9A and 9B are sectional views for explaining a state in which second hole 127 formed on second prepreg 125 is filled with a reuse paste through a second protective film. In FIG. 9A, second prepreg 125 is formed in a semi-curing state (that is, a B stage state) by impregnation of a glass woven fabric, a glass non-woven fabric, an aramid woven fabric or an aramid non-woven fabric with an epoxy resin or the like. Second projecting film 126 is a PET film or the like. For second protective film 126, more specifically, PET, PEN, PPS or the like is used. Second protective film 126 is formed on the surface of second prepreg 125 through thermocompression bonding while removing air by using a vacuum laminater or a roll laminater. Second hole 127 is formed by a carbon dioxide laser, a YAG laser or the like. In the case in which large second hole 127 is formed, moreover, a drill, a punch or the like may be used. First prepreg 101 and second prepreg 125 may be of the same type of the same manufacturer. First circuit board 115 formed by curing first prepreg 101 is thermally cured before second circuit board 133 is formed by curing second prepreg 125. Reuse paste 124 to be used in first prepreg 101 and second prepreg 125 may be set into an identical lot or different lots. In other words, “first” and “second” in first prepreg 101 and second prepreg 125 indicate “before” and “after” the step, respectively. In the present exemplary embodiment, reuse paste 124 is used for second prepreg 125 to fabricate second circuit board 133. However, reuse paste 124 may be used for first prepreg 101 to fabricate first circuit board 115.

Second protective film 126 is applied to both sides of second prepreg 125. In some cases, fiber piece 108 such as a glass fiber sticks to a surface of second protective film 126. In some cases, fiber piece 108 cannot be completely removed by means of a sucking device or an adhesive roll (neither of which are shown).

As illustrated in FIG. 9B, jig 104 is moved in a direction shown in arrow 607 over second protective film 126 to which fiber piece 108 sticks and second hole 127 is thus filled with reuse paste 124. As shown in FIG. 9B, by increasing a contact pressure (or a pushing pressure) of jig 104 against second protective film 126, it is possible to accommodate fiber piece 108 on second protective film 126 in reuse paste 124. Also in the case in which fiber piece 108 is accommodated in reuse paste 124, fiber piece 108 can be removed as shown in FIGS. 6 to 8. As a result, it is possible to fabricate a second reuse paste (not shown), and furthermore, a third reuse paste (not shown) for repeating recycle of the paste. By repeating the reuse of conductive paste 105, thus, it is possible to reduce an amount of industrial wastes to be discarded as a waste paste. Therefore, it is possible to take a countermeasure against an environment and to reduce a manufacturing cost. The reuse of conductive paste 105 indicates removal of fiber piece 108 or the like and readjustment of composition of conductive paste 105 without influencing a shape or dispersion state of the conductive powder contained in conductive paste 105.

FIGS. 10A to 10C are sectional views for explaining a state in which a second circuit board is manufactured by using reuse paste 124. In FIG. 10A, second protruded portion 129 constituted of reuse paste 124 is formed on second prepreg 125. Second copper foil 128 is provided as a metallic foil on both sides of second prepreg 125.

By carrying out pressurization (and furthermore, desirably heating) in a direction shown in arrow 707, a state shown in FIG. 10B is brought. As shown in FIG. 10B, reuse paste 124 is compressed and cured so that second via 131 is formed, and furthermore, second prepreg 125 is cured so that second insulating layer 130 is formed.

Second copper foil 128 shown in FIG. 10B is formed into a predetermined pattern through etching or the like so that second wiring 132 in FIG. 10C is obtained. Thus, second circuit board 133 is manufactured.

FIGS. 11A to 11C are views for explaining a method of manufacturing a multilayer board having four wiring layers. As shown in FIG. 11A, second prepreg 125 having second protruded portion 129 and second copper foil 128 are set onto both sides of first wiring board 115, and pressurization and integration are carried out in a direction of arrow 807. In the pressurization, heating may be performed.

FIG. 11B is a sectional view showing a state in which second prepreg 125 is cured so that second insulating layer 130 is obtained. Then, second copper foil 128 on a surface layer is etched into second wiring 132 so that second wiring board 133 shown in FIG. 11C is obtained. By repeating the steps, moreover, it is possible to further make a multilayer.

Referring to FIGS. 12A and 12B, next, recovery pastes 119 a to 119 d will be described in more detail with reference to a view showing an SEM observation image.

FIGS. 12A and 12B are a view showing an SEM observation image of a part of the recovery paste and a typical view thereof. Recovery pastes 119 a to 119 d contain conductive powder 134 constituted of copper powder or the like and fiber piece 108 constituted of a glass fiber or the like.

A particle diameter or shape of conductive powder 134, a particle diameter distribution or the like can be optimized depending on respective uses. As shown in FIGS. 12A and 12B, the particle diameter of conductive powder 134 is almost equal to a diameter of fiber piece 108. Moreover, a length of fiber piece 108 is approximately five times as great as the diameter (or ten times or more). In other words, fiber piece 108 is extended in a length direction as compared with the diameter. Furthermore, particulate conductive powder 134 takes a spherical shape in which a diameter and a length are almost equal to each other. In the present exemplary embodiment, a difference between the shapes of fiber piece 108 and conductive powder 134 is utilized.

In the present exemplary embodiment, waste paste to be conventionally discarded is recovered and collected as recovery pastes 119 a to 119 d to form recovered composite paste 120. Fiber piece 108 is selectively removed from recovered composite paste 120; a viscosity, a solid content, a composition ratio or the like is adjusted, and reproduction is carried out to obtain a reuse paste so that a circuit board is manufactured.

In the present exemplary embodiment, fiber piece housing pastes 109 generated in the steps in FIGS. 1A to 3C to be the steps of manufacturing first circuit board 115, that is, recovery pastes 119 a to 119 d having fiber piece 108 mixed therein as shown in FIGS. 12A and 12B are reproduced in the steps shown in FIGS. 6 to 8. Then, reuse paste 124 is utilized in the process for manufacturing second circuit board 133 as shown in FIGS. 9A to 11C.

FIGS. 13A to 13C are typical views for explaining filling of a conductive paste according to a comparative example. First prepreg 101 having first hole 103 formed thereon is fixed to base 106 and jig 104 is moved in a direction of arrow 907 so that first hole 103 is filled with conductive paste 105.

In FIG. 13A, fiber piece 108 sticking onto first protective film 102 is mixed into conductive paste 105. As a result, a viscosity is higher than a normalized value in a manufacturing specification. Additional paste 135 is used for reducing a viscosity, and the viscosity of additional paste 135 is lower than that of conductive paste 105 to be added.

FIG. 13B is a sectional view showing a state in which additional paste 135 having a lower viscosity than conductive paste 105 having a higher viscosity than the normalized value is added to conductive paste 105. Added paste 136 is obtained by adding additional paste 135 having a lower viscosity than the normalized value to conductive paste 105 having the higher viscosity than the normalized value in the manufacturing specification. A viscosity of added paste 136 is in a range of the normalized value in the manufacturing specification through the addition of additional paste 135. It is also possible to include a composition ratio of a paste within the normalized value in the manufacturing specification as well as the viscosity range by addition of additional paste 135.

FIG. 13C is a typical view for explaining a problem caused by added paste 136.

As shown in FIG. 13C, unfilled portion 137 or air gap 138 is generated when first hole 103 formed on first prepreg 101 is filled with additional paste 136 in some cases. The reason is supposed as follows. As shown in FIG. 13, a large number of fiber pieces 108 are mixed in added paste 136. Even if additional paste 135 is simply added, it is impossible to exclude the influence of fiber piece 108 mixed in conductive paste 105.

In the case in which the viscosity of the conductive paste before printing is 15 (Pa·s), moreover, a viscosity of approximately 89 (Pa·s) is obtained after printing 250 sheets (see Table 1 which will be described below). Even if a new conductive paste is simply added without adjustment of the viscosity of the conductive paste after printing 250 sheets, the viscosity is made higher than 50 (Pa·s). In some cases in which the viscosity is high, a filling property for first hole 103 is influenced. In the case in which the initial viscosity of the reuse paste exceeds 50 Pa·s, the number of sheets which can be printed subsequently is decreased. For this reason, it is preferable that a viscosity before the start of print should be adjusted to be equal to or higher than 5 (Pa·s) and to be equal to or lower than 50 (Pa·s). In other words, in the present exemplary embodiment, it is important to adjust a viscosity of a used conductive paste and to filter the used conductive paste by using a filter.

Reuse according to the present exemplary embodiment will be described below. The present invention does not propose the simple reuse of a used conductive paste but any of technical ideas utilizing a natural law which is advanced for the reuse. It is supposed that reduction in the amount of discard of the conductive paste, and furthermore, the reuse thereof in the present invention correspond to reuse, that is, reuse with the same object as that in the beginning including continuous use in EU (for example, the WEE directive, Article 7).

In the EU (for example, the WEE directive, Article 7), particularly, recycle is divided into two parts, that is, recovery and disposal. Moreover, the recovery is divided into three parts, that is, reuse, recycling and energy recovery. Herein, the disposal implies redemption or reclamation. The reuse implies that use is carried out again for the same object as that in the beginning including the continuous use. The recycle implies that a waste material is reprocessed at a producing step for the object in the beginning or the other object. The energy recovery implies energy recovery through direct combustion accompanied by thermal recovery.

The present exemplary embodiment corresponds to recovery based on the EU recycle definition and is useful for reduction in wastes or the like or reduction in consumption of resource energy or the like.

Even if a conductive paste is simply mixed into a conductive paste which is used (or is being used) over a metal mask having a smaller opening portion than a printed body, a fiber piece or the like which is mixed (stored) into the conductive paste cannot be removed. For this reason, the used conductive paste (or the conductive paste to be reused) according to the present exemplary embodiment is recovered to an outside of a printing machine through a metal mask provided around the printed body or the like.

In the present exemplary embodiment, the used conductive paste is taken out (or recovered) through the metal mask provided around the printed body or the like (and furthermore, a used printing machine, squeegee or the like), and the conductive paste is recycled (particularly, reused) on the outside of the printing machine (or another place, another device). Thus, the used conductive paste is taken out so that the used conductive pastes generated in a plurality of different print lots on different days and times are efficiently recovered and are thus collected into a single large lot (1 kg or more, 5 kg or more, and furthermore, 10 kg or more). Therefore, it is possible to enhance efficiency and a yield of the recycle (particularly, reuse) of the conductive paste. The used conductive paste is generated in a small amount (for example, less than 1 kg, and furthermore, 500 g to 50 g) after the end of print. In the case in which the print is carried out by using the squeegee, the conductive paste is scattered discontinuously over a straight contact surface of the squeegee and the printed body so that filling into a hold formed on a prepreg cannot be carried out if the amount of the conductive paste is decreased. By collecting a plurality of conductive pastes in small amounts to increase the amount (1 kg or more, and furthermore, 10 kg or more) in place of the recovery in the small amount, it is possible to remove a fiber piece or the like in the used paste with high efficiency.

According to the present exemplary embodiment, the recovered conductive paste is reproduced to enable reuse with a dispersion state of a conductive particle maintained as it is, and an advanced technical idea is proposed.

The present exemplary embodiment will be described below in more detail. (Table 1) to (Table 5) indicate an example of a result obtained by an experiment for the effects in the present exemplary embodiment.

The (Table 1) to (Table 5) indicate diameters of holes formed on a prepreg and the number of the holes, and a defect ratio in the case in which the number of printed sheets is varied. Moreover, a right end of the table indicates a viscosity for each number of printed sheets. By using a rheometer of a cone plate type, an apparent viscosity at 0.5 rpm is measured. A unit of the viscosity is Pa·s. A diameter of a cone of the rheometer of the cone plate type is 25 mm and a cone angle is 2 degrees. A measuring temperature of a sample is 25° C. A measurement of the viscosity or the like is based on JIS K7117-2.

On a prepreg (500 mm×600 mm) are formed 50000 holes in total, that is, 10000 holes having a diameter of 80 μm, 10000 holes having a diameter of 100 μm, 10000 holes having a diameter of 130 μm, 10000 holes having a diameter of 150 μm, and 10000 holes having a diameter of 200 μm. The (Table 1) shows results obtained by evaluating them using a test pattern capable of carrying out evaluation in a single prepreg. In the (Table 1), the number of vias which have conduction defect is measured in 10000 holes. There is not used a via chain pattern which is generally utilized widely, that is, a test pattern for measuring whether at least one of 10000 continuous vias is disconnected or not. In the case in which 10000 vias having the diameter of 130 μm are formed, moreover, a yield obtained in print of 350 sheets is set to be 1.0 as normalization. For this reason, a unit is not given to the defect ratio in the (Table 1). In the (Table 1), φ represents a diameter of a hole.

TABLE 1 Number of printed φ80 μm × φ100 μm × φ130 μm × φ150 μm × φ200 μm × Viscosity sheets (Sheet) 10000 10000 10000 10000 10000 (Pa · s) 0 — — — — — 15 50 0 0 0 0 0 20 100 0 0 0 0 0 32 150 0 0 0 0 0 42 200 0 0 0 0 0 69 250 0 0 0 0 0 89 300 7.5 1.7 0 0 0 137 350 14.5 5.8 1.0 (normalized 0 0 169 value) 400 33.2 9.9 3.8 1.2 0 247 450 63.9 21.4 10.3 3.8 0.9 511

From the result for the 50th printed sheet in the (Table 1), a defect is not generated in the case of the holes having the diameters of 80 μm to 200 μm. At that time, the viscosity is 20 (Pa·s).

From the result for the 250th printed sheet in the (Table 1), a defect is not generated in the case of the holes having the diameters of 80 μm to 200 μm. At that time, the viscosity is 89 (Pa·s). It is apparent that the viscosity is increased when the number of the printed sheets is increased.

From the result for the 300th printed sheet in the (Table 1), the defect ratio is 7.5 in the case of the hole having the diameter of 80 μm, and the defect ratio is 1.7 in the case of the hole having the diameter of 100 μm. The defect is not generated in the case of the holes having the diameters of 130 μm to 200 μm. As described above, it is apparent that the number of the printed sheets is increased to 300 so that the defect ratio is increased when the diameter of the hole is decreased. Moreover, the viscosity is 137 (Pa·s) when the number of the printed sheets is 300, and the defect is not generated for the 300th sheet in the case of the holes having the diameters 130 μm to 200 μm. The defect is generated when the diameter of the hole is equal to or smaller than 100 μm, and the defect is not generated when the diameter of the hole is equal to or larger than 130 μm. The reason is supposed as follows. The holes having the diameters of 130 μm to 200 μm have larger diameters than the diameters of 80 μm to 100 μm. Also in the case in which the viscosity of the conductive paste is increased to 137 (Pa·s), therefore, the conductive paste can be reliably filled into the holes.

From the result for 350 printed sheets in the (Table 1), the defect ratio is 14.5 in the case of 10000 holes having the diameter of 80 μm, is 5.8 in the case of 10000 holes having the diameter of 100 μm, and is 1.0 in the case of 10000 holes having the diameter of 130 μm (which value is normalized to be 1.0). In the case of the holes having the diameters of 150 μm and 200 μm, the defect ratio is zero. The reason is supposed as follows. Irrespective of further increase in the viscosity of the paste to 169 (Pa·s), the diameter of the hole is large, that is, 150 μm or more. Therefore, the conductive paste can reliably be filled into the hole.

From the result for 400 printed sheets in the (Table 1), the defect ratio is 33.2 in the case of 10000 holes having the diameter of 80 μm, is 9.9 in the case of 10000 holes having the diameter of 100 μm, is 3.8 in the case of 10000 holes having the diameter of 130 μm, and is 1.2 in the case of 10000 holes having the diameter of 150 μm. In the case of the hole having the diameter of 200 μm, the defect ratio is zero. The reason is supposed as follows. Irrespective of further increase in the viscosity of the paste to 247 (Pa·s), the diameter of the hole is large, that is, 200 μm. Therefore, the conductive paste can reliably be filled into the hole.

From the result for 450 printed sheets in the (Table 1), the defect ratio is 63.9 in the case of 10000 holes having the diameter of 80 μm, is 21.4 in the case of 10000 holes having the diameter of 100 μm, is 10.3 in the case of 10000 holes having the diameter of 130 μm, is 3.8 in the case of 10000 holes having the diameter of 150 μm, and is 0.9 in the case of 10000 holes having the diameter of 200 μm. Also in the case of the hole having the diameter of 200 μm, the defect is generated. The reason is supposed as follows. When 450 sheets are printed, an ink viscosity is greatly increased to 511 (Pa·s). Although the diameter of the hole is large, that is, 200 μm, therefore, the conductive paste cannot be completely filled into the hole in some cases.

The defect is not generated with the viscosity of the conductive paste of 89 (Pa·s) if the diameter of the hole is smaller than 130 μm, and the defect is generated with the viscosity of the conductive paste of 137 (Pa·s). Accordingly, it is desirable that the conductive paste which is not filled in the hole should be recovered as a recovery paste when the viscosity of the conductive paste is approximately 80 (Pa·s) or more. The initial viscosity of the conductive paste (before the start of the print) is 15 (Pa·s). In the case in which the viscosity is approximately five times as high as the initial viscosity or more, therefore, it is preferable that the conductive paste which is not filled in the hole should be recovered as the recovery paste.

In the case in which the diameter of the hole is equal to or greater than 130 μm and is smaller than 150 μM, the defect is not generated in the viscosity of the conductive paste of 137 (Pa·s), but is generated in the viscosity of the conductive paste of 169 (Pa·s). Accordingly, it is desirable that the conductive paste which is not filled in the hole should be recovered as a recovery paste when the viscosity of the conductive paste is approximately 130 (Pa·s) or more. The initial viscosity of the conductive paste is 15 (Pa·s). In the case in which the viscosity is approximately eight times as high as the initial viscosity or more, therefore, it is preferable that the conductive paste which is not filled in the hole should be recovered as the recovery paste.

In the case in which the diameter of the hole is equal to or greater than 150 μm and is smaller than 200 μm, the defect is not generated in the viscosity of the conductive paste of 169 (Pa·s), but is generated in the viscosity of the conductive paste of 247 (Pa·s). Accordingly, it is desirable that the conductive paste which is not filled in the hole should be recovered as a recovery paste when the viscosity of the conductive paste is approximately 160 (Pa·s) or more. The initial viscosity of the conductive paste is 15 (Pa·s). In the case in which the viscosity is approximately ten times as high as the initial viscosity or more, therefore, it is preferable that the conductive paste which is not filled in the hole should be recovered as the recovery paste.

In the case in which the diameter of the hole is equal to or greater than 200 μm, the defect is not generated in the viscosity of the conductive paste of 247 (Pa·s), but is generated in the viscosity of the conductive paste of 511 (Pa·s). Accordingly, it is desirable that the conductive paste which is not filled in the hole should be recovered as a recovery paste when the viscosity of the conductive paste is approximately 240 (Pa·s) or more. The initial viscosity of the conductive paste is 15 (Pa·s). In the case in which the viscosity is approximately 16 times as high as the initial viscosity or more, therefore, it is preferable that the conductive paste which is not filled in the hole should be recovered as the recovery paste.

In some cases, it is hard to obtain a measured value of the viscosity accurately at each time in the steps. In these cases, the initial viscosity (before the start of the print) is set to be one. It is useful that a viscosity after the print is measured as compared with the initial viscosity and the conductive paste which is not filled is recovered as the recovery paste. Although the viscosity before the start of the print is set to be one, a viscosity obtained after printing a certain number of (for example, ten) sheets may be set to be one.

As shown in the (Table 1), moreover, it is also possible to check a relationship between the viscosity and the number of the printed sheets in which the defect is generated, recovering, as the recovery paste, the conductive paste which is not filled in the hole after printing a certain number of sheets.

The diameter of the hole of 80 μm represents 80 μm±8 μm in detail. Moreover, the diameter of the hole of 100 μm represents 100 μm±10 μm in detail. Moreover, the diameter of the hole of 130 μm represents 130 μm±13 μm in detail. In addition, 150 μm represents 150 μm±15 μm in detail. Moreover, 200 μm represents 200 μm±20 μm in detail. The reason is that the diameter of the hole has a variation in some cases. It is useful that the diameter of the hole is set to be a diameter in a portion in which a sectional area of the hole is minimized.

In the case in which the number of the sheets is equal to or larger than a certain number, conventionally, the conductive paste is discarded irrespective of the diameter of the hole. Also in the used conductive paste in which the defect is generated in a small hole having the diameter of 80 μm, the defect is not generated in a comparatively large hole having the diameter of 200 μm in some cases. However, a conductive paste which can be used by selecting a diameter of a hole is also discarded conventionally in many cases.

In the present exemplary embodiment, the conductive paste exceeding the number of the printed sheets, that is, 450 in the (Table 1) which are conventionally discarded is recovered as recovery pastes 119 a to 119 d. Furthermore, the conductive paste is united with a used conductive paste in another lot to prepare approximately 10 kg of recovered composite paste 120. Viscosities of individual recovery pastes 119 a to 119 d are greatly varied to be approximately 600 to 800 (Pa·s).

In order to remove fiber piece 108 mixed into recovered composite paste 120 and formed of a glass fiber having a length of 100 μm or more, therefore, filter 121 having 100 meshes is used to carry out filtering as shown in FIG. 7 so that filtered recovery paste 122 is obtained.

As shown in FIG. 8, then, the viscosity is adjusted. By using thermogravimetry (TG) or the like, moreover, a degree of composition deviation in the conductive paste is measured and solvent or the like 123 is added to adjust the viscosity against the composition deviation. This is set to be a reuse paste for first recovery and the same printing experiment as the (Table 1) is carried out. The result is shown in (Table 2). In the (Table 2), for example, the description of the number of printed sheets of 450+50=500 sheets in a first column indicates that 50 sheets are printed as a first reuse paste. In other words, it is implied that 450 sheets have already been printed previously (that is, when the conductive paste is brand-new) even if 50 sheets are printed newly as the first reuse paste. Consequently, the print of 50 sheets with the first reuse paste corresponds to the print of 50+450=500 sheets in total.

TABLE 2 Number of printed φ80 μm × φ100 μm × φ130 μm × φ150 μm × φ200 μm × Viscosity sheets (Sheet) 10000 10000 10000 10000 10000 (Pa · s) After adjustment — — — — — 20 of viscosity 450 + 50 = 500 0 0 0 0 0 29 450 + 100 = 550 0 0 0 0 0 51 450 + 150 = 600 0 0 0 0 0 74 450 + 200 = 650 0 0 0 0 0 100 450 + 250 = 700 6.5 1.2 0 0 0 125 450 + 300 = 750 20.0 10.5 1.6 0.1 0 212 450 + 350 = 800 33.3 16.5 7.9 1.6 0.1 345 450 + 400 = 850 66.7 30.6 21.3 12.5 1.2 500 450 + 450 = 900 200.0 76.7 36.5 14.1 2.3 714

Description will be given to a column of the number of the printed sheets of 450 (the number of the printed sheets in a brand-new product)+200 (the number of the printed sheets as a reuse paste)=650 (the total number of the printed sheets) in the (Table 2). In the case in which a hole having a diameter of 80 μm to 200 μm is used in the number of the printed sheets of 200 or less even with the reuse paste for the first reuse, a defect is not generated. The number of the printed sheets of 200 with the reuse paste for the first reuse actually corresponds to the print for 650 sheets because the print for 450 sheets is finished in a brand-new product.

In the case of the hole having the diameter of 80 μm, a defect ratio is 63.9 when the number of the printed sheets is 450 in the (Table 1), and the defect ratio is zero when the number of the printed sheets is 450+200=650 in the (Table 2). In the present exemplary embodiment, thus, by using a small diameter of 80 μm in which the defect ratio tends to be increased, it is possible to sharply decrease the defect ratio also in the case in which the number of the printed sheets is increased.

Next, description will be given to a column of the number of the printed sheets of 450 (the number of the printed sheets in the brand-new product)+400 (the number of the printed sheets as the reuse paste)=850 (the total number of the printed sheets) in the (Table 2). In the reuse paste at a first time for reuse, when the number of the printed sheets is 400, the defect ratio is 66.7 in the case of the hole having the diameter of 80 μm, is 30.6 in the case of the hole having the diameter of 100 μm, is 21.3 in the case of the hole having the diameter of 130 μm, is 12.5 in the case of the hole having the diameter of 150 μm, and is 1.2 in the case of the hole having the diameter of 200 μm. Even with the reuse paste, similarly, it is apparent that the defect ratio is increased when the number of the printed sheets is increased, particularly, the diameter of the hole is reduced.

In the (Table 2), the viscosity of the reuse paste is adjusted to be equal to or more than 5 (Pa·s) and to be equal to or less than 50 (Pa·s). In some cases in which the viscosity of the reuse paste is less than 5 (Pa·s), a solid content is decreased to influence a via resistance. In some cases in which the viscosity is high, moreover, a filling property for the via hole is influenced. In the case in which the initial viscosity of the reuse paste exceeds 50 Pa·s, the number of sheets which can be printed subsequently is decreased. Accordingly, it is preferable that the viscosity before the start of the print should be adjusted to be equal to or more than 5 (Pa·s) and to be equal to or less than 50 (Pa·s). It is desirable that the viscosity of the reuse paste should be set into a range of 5 (Pa·s) or more and 50 (Pa·s) or less, and furthermore, the solid content should be adapted to a range of ±1 wt % or less of the solid content of a brand-new conductive paste (for example, 85 wt % or more and 95 wt %).

The defect is not generated with the viscosity of the conductive paste of 100 (Pa·s) if the diameter of the hole is smaller than 130 μm, and the defect is generated with the viscosity of the conductive paste of 125 (Pa·s). Accordingly, it is desirable that the conductive paste which is not filled in the hole should be recovered as a recovery paste when the viscosity of the conductive paste is approximately 100 (Pa·s) or more. The conductive paste before the start of the print in the reuse paste has a viscosity of 20 (Pa·s). In the case in which the viscosity is approximately five times as high as the viscosity before the start of the print in the reuse paste or more, therefore, it is preferable that the conductive paste which is not filled in the hole should be recovered as the recovery paste.

In the case in which the diameter of the hole is equal to or greater than 130 μm and is smaller than 200 μm, the defect is not generated in the viscosity of the conductive paste of 125 (Pa·s), but is generated in the viscosity of the conductive paste of 212 (Pa·s). Accordingly, it is desirable that the conductive paste which is not filled in the hole should be recovered as a recovery paste when the viscosity of the conductive paste is approximately 120 (Pa·s) or more. The conductive paste before the start of the print in the reuse paste has a viscosity of 20 (Pa·s). In the case in which the viscosity is approximately six times as high as the viscosity before the start of the print in the reuse paste or more, therefore, it is preferable that the conductive paste which is not filled in the hole should be recovered as the recovery paste.

In the case in which the diameter of the hole is equal to or greater than 200 μm, the defect is not generated in the viscosity of the conductive paste of 212 (Pa·s), but is generated in the viscosity of the conductive paste of 345 (Pa·s). Accordingly, it is desirable that the conductive paste which is not filled in the hole should be recovered as a recovery paste when the viscosity of the conductive paste is approximately 200 (Pa·s) or more. The conductive paste before the start of the print in the reuse paste has a viscosity of 20 (Pa·s). In the case in which the viscosity is approximately ten times as high as the viscosity before the start of the print in the reuse paste or more, therefore, it is preferable that the conductive paste which is not filled in the hole should be recovered as the recovery paste.

In some cases, it is hard to obtain a measured value of the viscosity accurately at each time in the steps. In these cases, the viscosity before the start of the print of the reuse paste is set to be one. It is useful that a viscosity after the print is measured as compared with the viscosity before the start of the print of the reuse paste and the conductive paste which is not filled is recovered as the recovery paste. Although the viscosity before the start of the print of the reuse paste is set to be one, a viscosity obtained after printing a certain number of (for example, ten) sheets may be set to be one.

As shown in the (Table 2), moreover, it is also possible to check a relationship between the viscosity and the number of the printed sheets in which the defect is generated, recovering, as the recovery paste, the conductive paste which is not filled in the hole after printing a certain number of sheets.

However, the result of the (Table 2) is obtained after 450 sheets are printed in the brand-new product. As compared with the (Table 1), therefore, it is apparent that the number of the printed sheets is increased to be almost a double.

Next, description will be given to a column of the number of the printed sheets of 450 (the number of the printed sheets in the brand-new product)+450 (the number of the printed sheets as the reuse paste)=900 (the total number of the printed sheets) in the (Table 2). Even with the reuse paste for the first reuse, similarly, the defect ratio is increased when 450 sheets (900 sheets in total) are printed.

For this reason, the conductive paste carrying out the print for 900 sheets in total is set to be recovered composite paste 120 as shown in FIG. 6, and filtering is performed to obtain filtered recovery paste 122 as shown in FIG. 7 by using filter 121 having 100 meshes in order to remove fiber piece 108. As shown in FIG. 8, then, the viscosity is adjusted. By using thermogravimetry (TG) or the like, moreover, a degree of composition deviation in the conductive paste is measured and solvent or the like 123 is added to adjust the viscosity against the composition deviation. This is set to be a reuse paste for second recovery. By using the reuse paste for the second reuse, the same printing experiment as that in the (Table 1) is carried out. The result is shown in (Table 3).

TABLE 3 Number of printed φ80 μm × φ100 μm × φ130 μm × φ150 μm × φ200 μm × Viscosity sheets (Sheet) 10000 10000 10000 10000 10000 (Pa · s) After adjustment — — — — — 35 of viscosity 900 + 50 = 950 0 0 0 0 0 51 900 + 100 = 1000 0 0 0 0 0 69 900 + 150 = 1050 0 0 0 0 0 110 900 + 200 = 1100 4.6 0.7 0 0 0 158 900 + 250 = 1150 12.5 9.4 2.7 0.7 0 215 900 + 300 = 1200 30.6 21.2 7.3 4.5 0.2 348 900 + 350 = 1250 82.7 56.5 17.8 11.6 1.2 501 900 + 400 = 1300 273.7 160.7 39.9 19.9 2.3 811 Not 900 + 450 = 1350 650.5 283.4 69.9 58.1 3.2 measured

Description will be given to a column of the number of the printed sheets of 900 (the number of the printed sheets in a brand-new product+the number of the printed sheets in first recovery)+150 (the number of the printed sheets as a reuse paste in second recovery)=1050 (the total number of the printed sheets) in the (Table 3). In the case in which a hole having a diameter of 80 μm to 200 μm is used in the number of the printed sheets of 150 or less even with the reuse paste for the second reuse, a defect is not generated. The number of the printed sheets of 150 with the reuse paste for the second reuse actually corresponds to print of 1050 sheets because the print for 450 sheets is finished as the reuse paste for the first recovery in the brand-new product.

As described above, it is apparent that the conductive paste generating the defect ratio with the increase in the number of the printed sheets can also be used for manufacturing a printed circuit board repetitively through repetition of the reproduction processing shown in FIGS. 6 to 8.

The defect is not generated with the viscosity of the conductive paste of 110 (Pa·s) if the diameter of the hole is smaller than 130 μm, and the defect is generated with the viscosity of the conductive paste of 158 (Pa·s). Accordingly, it is desirable that the conductive paste which is not filled in the hole should be recovered as a recovery paste when the viscosity of the conductive paste is approximately 110 (Pa·s) or more. The conductive paste before the start of the print in the paste for the second reuse has a viscosity of 35 (Pa·s). In the case in which the viscosity is approximately three times as high as the viscosity before the start of the print in the paste for the second reuse or more, therefore, it is preferable that the conductive paste which is not filled in the hole should be recovered as the recovery paste.

In the case in which the diameter of the hole is equal to or greater than 130 μm and is smaller than 200 μm, the defect is not generated in the viscosity of the conductive paste of 158 (Pa·s), but is generated in the viscosity of the conductive paste of 215 (Pa·s). Accordingly, it is desirable that the conductive paste which is not filled in the hole should be recovered as a recovery paste when the viscosity of the conductive paste is approximately 150 (Pa·s) or more. The conductive paste before the start of the print in the paste for the second reuse has a viscosity of 35 (Pa·s). In the case in which the viscosity is approximately four times as high as the viscosity before the start of the print in the paste for the second reuse or more, therefore, it is preferable that the conductive paste which is not filled in the hole should be recovered as the recovery paste.

In the case in which the diameter of the hole is equal to or greater than 200 μm, the defect is not generated in the viscosity of the conductive paste of 215 (Pa·s), but is generated in the viscosity of the conductive paste of 348 (Pa·s). Accordingly, it is desirable that the conductive paste which is not filled in the hole should be recovered as a recovery paste when the viscosity of the conductive paste is approximately 210 (Pa·s) or more. The conductive paste before the start of the print in the paste for the second reuse has a viscosity of 35 (Pa·s). In the case in which the viscosity is approximately six times as high as the viscosity before the start of the print in the paste for the second reuse or more, therefore, it is preferable that the conductive paste which is not filled in the hole should be recovered as the recovery paste.

In some cases, it is hard to obtain a measured value of the viscosity accurately at each time in the steps. In these cases, the viscosity before the start of the print of the paste for the second reuse is set to be one. It is useful that a viscosity after the print is measured as compared with the viscosity before the start of the print in the paste for the second reuse and the conductive paste which is not filled is recovered as the recovery paste. Although the viscosity before the start of the print in the paste for the second reuse is set to be one, a viscosity obtained after printing a certain number of (for example, ten) sheets may be set to be one.

As shown in the (Table 3), moreover, it is also possible to check a relationship between the viscosity and the number of the printed sheets in which the defect is generated, recovering, as the recovery paste, the conductive paste which is not filled in the hole after printing a certain number of sheets.

With reference to (Table 4) and (Table 5), next, description will be given to the case in which a finer mesh (400 meshes) is used for filter 121 (see FIG. 7). By using the fine mesh, it is possible to selectively remove fiber piece 108 such as a glass fiber having a length of 20 μm to 30 μm or more.

By causing the mesh to be fine, it is possible to further increase a removal ratio of fiber piece 108 or the like which is mixed into recovered composite paste 120 (see FIG. 7). However, a time required for filtering is prolonged so that a yield obtained through the filtration is reduced in some cases. Therefore, utilization for different purposes is useful.

By combining a plurality of filters 121 having different meshes, moreover, it is possible to cause clogging with difficulty. In addition, the mesh does not need to be restricted to a shape of a net but it is also possible to use surface filtration, depth filtration, cake filtration (a glass fiber or the like deposited on a surface of a filter is set to be a cake, and the cake is utilized as a filter) or the like. For such a filtering material or filtering equipment, it is useful to improve a commercial product.

In order to remove fiber piece 108 mixed into recovered composite paste 120, filter 121 having 400 meshes is used to carry out the filtration as shown in FIG. 7 so that filtered recovery paste 122 is obtained.

As shown in FIG. 8, then, the viscosity is adjusted. By using thermogravimetry (TG) or the like, moreover, a degree of composition deviation in the conductive paste is measured and solvent or the like 123 is added to adjust the viscosity against the composition deviation. This is set to be a reuse paste for first recovery and the same printing experiment as the (Table 1) is carried out. The result is shown in (Table 4). In the (Table 4), for example, the description of the number of printed sheets of 450+50=500 sheets in a first column indicates that 50 sheets are printed as a first reuse paste. In other words, it is implied that 450 sheets have already been printed previously (that is, when the conductive paste is brand-new) even if 50 sheets are printed newly as the first reuse paste. Consequently, the print of 50 sheets with the first reuse paste corresponds to the print of 50+450=500 sheets in total.

TABLE 4 Number of printed φ80 μm × φ100 μm × φ130 μm × φ150 μm × φ200 μm × Viscosity sheets (Sheet) 10000 10000 10000 10000 10000 (Pa · s) 450 + 50 = 500 0 0 0 0 0 23 450 + 100 = 550 0 0 0 0 0 33 450 + 150 = 600 0 0 0 0 0 42 450 + 200 = 650 0 0 0 0 0 65 450 + 250 = 700 0 0 0 0 0 92 450 + 300 = 750 10.1 0.7 0 0 0 132 450 + 350 = 800 13.4 4.6 1.1 0 0 174 450 + 400 = 850 34.1 9.9 4.6 1.6 0 251 450 + 450 = 900 56.1 24.3 10.9 2.6 0.5 515

Description will be given to a column of the number of the printed sheets of 450 (the number of the printed sheets in the brand-new product)+250 (the number of the printed sheets as a reuse paste for 400-mesh filtration)=700 (the total number of the printed sheets) in the (Table 4). The defect is not generated in the number of the printed sheets of 250 (the total number of the printed sheets of 700) or less when the holes having the diameters of 80 μm to 200 μm are used. Because fine filter 121 having 400 meshes is used for the filtration, moreover, it is possible to further lessen the glass fibers remaining in the reuse paste. For this reason, it is also possible to suppress a rise in the viscosity.

TABLE 5 Number of printed φ80 μm × φ100 μm × φ130 μm × φ150 μm × φ200 μm × Viscosity sheets (Sheet) 10000 10000 10000 10000 10000 (Pa · s) 900 + 50 = 950 0 0 0 0 0 25 900 + 100 = 1000 0 0 0 0 0 35 900 + 150 = 1050 0 0 0 0 0 41 900 + 200 = 1100 0 0 0 0 0 70 900 + 250 = 1150 0 0 0 0 0 98 900 + 300 = 1200 7.3 0 0 0 0 140 900 + 350 = 1250 12.7 6.3 0.7 0 0 180 900 + 400 = 1300 29.4 12.5 5.9 0.7 0 259 900 + 450 = 1350 52.6 20.7 9.8 4.0 1.3 518

Description will be given to a column of the number of the printed sheets of 900 (the number of the printed sheets in the brand-new product+a first time for recovery)+250 (the number of the printed sheets as a reuse paste for 400-mesh filtration)=1150 (the total number of the printed sheets) in the (Table 5). The defect is not generated in the number of the printed sheets 250 (the total number of the printed sheets of 1150) or less irrespective of repetition of the reproduction twice when the holes having the diameters of 80 μm to 200 μm are used. Because fine filter 121 having 400 meshes is used for the filtration, it is possible to further lessen the glass fibers remaining in the reuse paste. For this reason, it is also possible to suppress a rise in the viscosity.

As described above in the present exemplary embodiment, conductive paste 105 is recycled, and furthermore, reused. Consequently, it is possible to decrease the waste paste.

Moreover, fiber piece 108 is formed of a glass constituting first prepreg 101 or second prepreg 125 in many cases. For this reason, it is desirable that the opening diameter of filter 121 to be used in the filtering step should be three times as large as the average particle diameter of the metal particle contained in the conductive paste or more and should be equal to or smaller than twenty times as large as the average diameter of the fiber, moreover, ten times or less, and furthermore, five times or less. In the case in which the opening diameter of filter 121 is equal to or smaller than a double of the average particle diameter of the metal particle, filter 121 tends to be clogged. In some cases in which the opening diameter of filter 121 is larger than thirty times as large as the average diameter of the fiber, moreover, fiber piece 108 having a small length cannot be filtered completely. The opening diameter of filter 121, the average particle diameter of the metal particle, the diameter of the fiber or the like can be observed and measured through SEM or the like.

In first prepreg 101 and second prepreg 125, it is useful to vary at least one of a thickness of the prepreg itself and the number and density of glass fibers or aramid fibers constituting the prepreg (a weave, a density, the number of fibers, or the like). By using the prepregs having thicknesses, the numbers of fibers constituting the prepregs, densities or the like which are different from each other, it is possible to obtain various circuit boards.

Moreover, a via diameter of a single prepreg may be unified into one diameter. Alternatively, a plurality of via diameters which are different from each other may be formed in the single prepreg.

In the present embodiment, the protective film in the preparation of the fiber piece housing paste is described as the first protective film and the protective film in the fabrication of the circuit board by utilizing the reuse paste is described as the second protective film. However, the protective film in the preparation of the fiber piece housing paste may be described as the second protective film and the protective film in the fabrication of the circuit board by utilizing the reuse paste may be described as the first protective film.

In the present embodiment, moreover, the hole to be formed on the prepreg in the preparation of the fiber piece housing paste is described as the first hole and the hole to be formed on the prepreg in the fabrication of the circuit board by utilizing the reuse paste is described as the second hole. However, the hole to be formed on the prepreg in the preparation of the fiber piece housing paste may be described as the second hole and the hole to be formed on the prepreg in the fabrication of the circuit board by utilizing the reuse paste may be described as the first hole.

INDUSTRIAL APPLICABILITY

A method of manufacturing a reuse paste according to the present exemplary embodiment can decrease a fiber piece mixed into a conductive paste in a circuit board using the conductive paste to connect layers. As a result, a yield can be enhanced. In addition, it is possible to reuse the conductive paste having the fiber piece mixed therein. Therefore, it is possible to considerably cut down a cost of a material for the circuit board and to reduce an amount of wastes.

REFERENCE MARKS IN THE DRAWINGS 101 first prepreg 102 first protective film 103 first hole 104 jig 105 conductive paste 106 base 107, 107b, 207, 307, 407, 507, arrow 607, 707, 807, 907 108, 108a, 108b, 108c, 108d fiber piece 109 fiber piece housing paste 110 first copper foil 111 first protruded portion 112 first insulating layer 113 first via 114 first wiring 115 first circuit board 116a, 116b, 116c, 116d composition deviation paste 119a, 119b, 119c, 119d recovery paste 120 recovered composite paste 121 filter 122 filtered recovery paste 123 solvent or the like 124 reuse paste 125 second prepreg 126 second protective film 127 second hole 128 second copper foil 129 second protruded portion 130 second insulating layer 131 second via 132 second wiring 133 second circuit board 134 conductive powder 135 additional paste 136 added paste 137 unfilled portion 138 air gap 

The invention claimed is:
 1. A method of manufacturing a circuit board comprising the steps of: preparing a fiber piece housing paste including a conductive paste having conductive powder and a resin and a fiber piece taken away from a first prepreg; filtering the fiber piece housing paste in a paste state by using a filter to remove the fiber piece from the fiber piece housing paste for fabricating a filtered recovery paste; adding at least one of a solvent, a resin, and a paste having a different composition from the filtered recovery paste to the filtered recovery paste for fabricating a reuse paste; sticking a first protective film to a surface of a second prepreg; forming a first hole on the second prepreg through the first protective film; filling the first hole with the reuse paste; peeling the first protective film to form a protruded portion constituted of the reuse paste on the surface of the second prepreg; disposing a metallic foil on both sides of the second prepreg to pressurize the second prepreg from an outside of the metallic foil; heating the second prepreg to cure the second prepreg and the reuse paste; and processing the metallic foil into a wiring pattern.
 2. The method of manufacturing a circuit board according to claim 1, wherein the fiber piece housing paste is prepared in such a manner that a fiber having a length of ten times as great as an average particle diameter of the conductive powder or more is contained in the fiber piece housing paste is 50 wt % or more of all of the fiber pieces in the fiber piece housing paste.
 3. The method of manufacturing a circuit board according to claim 1, wherein the fiber piece housing paste is prepared in such a manner that a fiber having a length of ten times as great as an average particle diameter of the conductive powder or more is contained in the fiber piece housing paste is equal to or more than 0.01 wt % and is equal to or less than 10 wt % of the fiber piece housing paste.
 4. The method of manufacturing a circuit board according to claim 1, wherein the reuse paste is fabricated in such a manner that a fiber having a length of ten times as great as an average particle diameter of the conductive powder or more is contained in the reuse paste is equal to or less than 10 wt % of all fiber pieces in the reuse paste.
 5. The method of manufacturing a circuit board according to claim 1, wherein a viscosity of the reuse paste is equal to or more than 5 Pa·s and is equal to or less than 50 Pa·s.
 6. The method of manufacturing a circuit board according to claim 1, wherein the fiber piece housing paste is held at a temperature ranging from 0° C. to 80° C. inclusive in the step of fabricating a filtered recovery paste.
 7. The method of manufacturing a circuit board according to claim 1, wherein an opening diameter of the filter is three times as great as an average particle diameter of the metal particle or more and is 20 times as great as an average diameter of the fiber piece or less.
 8. The method of manufacturing a circuit board according to claim 1, wherein the fiber piece contained in the fiber piece housing paste is a glass fiber or an aramid fiber.
 9. The method of manufacturing a circuit board according to claim 1, wherein the filter is net-like stainless or polyester.
 10. The method of manufacturing a circuit board according to claim 1, wherein the resin in the conductive paste is a thermosetting resin.
 11. The method of manufacturing a circuit board according to claim 1, wherein a latent curing agent is used as a curing agent of the resin in the conductive paste, and an opening diameter of the filter is three times as great as an average particle diameter of the metal particle or more, is 20 times as great as an average diameter of the fiber piece or less, and is a double of a diameter of the latent curing agent or more.
 12. The method of manufacturing a circuit board according to claim 1, wherein the solvent is the same as that contained in the conductive paste.
 13. The method of manufacturing a circuit board according to claim 1, wherein the solvent is diethylene glycol monobutyl ether.
 14. The method of manufacturing a circuit board according to claim 1, wherein the resin to be added to the filtered recovery paste is the same as that contained in the conductive paste.
 15. The method of manufacturing a circuit board according to claim 1, wherein the resin to be added to the filtered recovery paste is an epoxy resin.
 16. The method of manufacturing a circuit board according to claim 1, further comprising the step of measuring a viscosity of the fiber piece housing paste between the preparation of the fiber piece housing paste and the fabrication of the filtered recovery paste, and when the measurement finds the viscosity not smaller than a predetermined value, the step moves on to the fabrication of the filtered recovery paste.
 17. The method of manufacturing a circuit board according to claim 1, further comprising the step of measuring a viscosity of the fiber piece housing paste between the preparation of the fiber piece housing paste and the fabrication of the filtered recovery paste, when the measurement finds the viscosity not smaller than a value predetermined times as great as that of the conductive paste, the step moves on to the fabrication of the filtered recovery paste.
 18. The method of manufacturing a circuit board according to claim 1, wherein the fiber piece housing paste is obtained by recovering the conductive paste or the reuse paste which is not filled in a second hole after the step of sticking a second protective film to a surface of the first prepreg; the step of forming a second hole on the first prepreg through the second protective film; and the step of filling the second hole with the conductive paste or the reuse paste. 